Flat panel displays with primary viewing envelopes away from displyay panel normal

ABSTRACT

We disclose a flat panel display suitable for viewing primarily from viewing angles or envelopes that are away from the direction that is perpendicular to the display panel (display normal). We disclose a way of increase the brightness of the display at large viewing angles. It is desirable to have such a display when the display is primarily viewed from directions that are not along the display normal, such as in the case of the cockpit of a transport aircraft where a display could be viewed mostly from left and right by the pilot and co-pilot. The display uses a light re-distributor (LRD) to increase the brightness of the display at larger viewing angles. The LRD consists of light re-directing portion, light straight-transmission portion and light scattering portion. For transmissive or transflective displays, light rays from the backlight entering the LRD at the light-redirecting portions are redirected and the rays that hits the light straight-transmission portion pass the LRD without changing direction. The surface profile of the light-redirecting portion determined the viewing angles/envelopes at which the light is directed to. This surface profile and the ratio of the light-redirecting portion to the light straight-transmission portion determine how much light is redirected to the viewing angles. The light distribution can be further modified by introducing a diffuser, either by surface treatment or by laminating a diffuser film onto the LRD. The diffuser can be used to smooth out brightness sharp changes at the boundaries of primary and secondary viewing envelopes. Commercially available materials, light-redirecting films and diffuser films can be used to construct a LRD of desired light re-distributing properties, making the LRD a cost effective element of the display. The LRD can be used for displays other than LCD, such as light emitting displays where no backlight exists, by placing the LRD on top the front substrate of the display.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of flat paneldisplays. More specifically, the present invention discloses a techniqueusing a light re-distributor (LRD) for increasing the brightness of adisplay at viewing envelopes/angles that are away from the directionthat is perpendicular to the display panel (display normal).

2. Statement of the Problem

Normally, displays are brightest when viewed along the display normaldirection and brightness decreases with the increase of viewing angles.In the case of an LCD, a diffuser behind the display panel roughlydefines the angle distribution of the illumination. A good diffusergives approximately Lambertian distribution, that is, the brightness isproportional to cos²(θ), where θ is the angle between the viewingdirection and the display normal. The brightness of an actual displaymay decrease faster than the Lambertian distribution because of thereflection of the surfaces of the display panel in front of thediffuser. The luminance at the display normal can be a couple of timeslarger than the luminance at a large viewing angle, say 60° from thedisplay normal.

In certain situations, such as in the cockpit of a transport aircraft,the pilot's and the co-pilot's primary viewing directions can be at verylarge angles, say 50°, from left and right. The primary viewingenvelopes are then centered on the −50° and +50° degrees horizontal andthe viewing envelope centered on the display normal is secondary. Inother cases, such as displays in other types of aircrafts andautomobiles, the primary viewing directions can also be away from thedisplay normal. In all these cases, it is desirable to increase thebrightness at the primary viewing envelopes. In some cases, it is evenmore desirable for the display to be brighter at primary viewingenvelopes than at the secondary. A technique to boost the brightness ofthese primary viewing envelopes is of importance.

We disclose a method of increase the brightness of the primary viewingenvelopes away from display normal using a light re-distributor.

3. Prior Art

A scheme of redirecting light of display has been proposed in U.S. Pat.No. 5,303,322. A so-called image redirect film redirects the light to acertain angle of viewing [1]. FIG. 1 is a description of the prior art.Compare to the method disclosed in this application, the prior art hasthe following limitations: 1). It redirects light to one direction orenvelope but not to multiple directions or envelopes. 2). It can only beachieved with a special prismatic film and not with other opticalelements that can be more cost effective. 3). It shows an artifact thatwhen close to the cut-off angle, the brightness changes dramatically ifthe viewer moves his head slightly. This artifact may also causeluminance non-uniformity problem if the display is large or if a fewsmall displays is put side by side so that the total display areaextends a certain viewing angle range to a fixed eye position.

4. Solution to the Problem

The present invention provides a flat panel display that uses a lightre-distributor (LRD) to re-distribute light between the primary andsecondary viewing envelopes of a display. This approach successfullyaddresses the problem of a conventional display's being much brighter atthe display normal than at larger viewing angles and boosts up thebrightness of the display at larger viewing angles. The presentinvention has the following advantages:

-   -   (1) Increase the brightness of the display at the primary        viewing envelopes that are away from the display normal. For        displays primarily viewed from large viewing angles, or viewed        from a wide range of angles (such as TV set), this invention is        valuable.    -   (2) Reduce power consumption requirement because the required        brightness at primary envelopes can be achieved with a less        bright backlight so that it uses less power. And, running at a        lower backlight power, the backlight, and the display to a        certain degree, will have a longer lifetime.    -   (3) No disturbance to the overall lighting of the environment        where the viewer is in so that the viewing of other displays or        other information will not be affected. Without the use of this        invention, when the display achieves the brightness requirement        at the primary viewing envelopes, the brightness at the        secondary viewing envelope, i.e., around the display normal, can        be so bright that it interferes with the overall lighting.    -   (4) Cosmetic defects are less visible. While boost the        brightness at larger viewing angles, this invention reduces the        visibility of small manufacturing cosmetic defects in the        display panel by reducing the intensity of backlight        illumination at the display normal. Defects are much less        visible when backlight is less intense. This invention redirect        a portion of the light otherwise coming out of the display        normal to larger viewing angles so that they are less visible at        the display normal.    -   (5) Provides multiple ways of realizing the desired effects. It        is of low cost, easy to manufacture because of the fact that it        can be made of different kinds of and commercially available        materials.

SUMMARY OF THE INVENTION

An LCD consists of a display panel with driving electronics, a backlightassembly (for transmissive or transflective displays) and abezel/housing to hold everything together. The light from the backlightis spatially modulated by the pixels of the display panel to form thedesired information on the panel. The backlight consists of emitter(s)with some optical components such as a light guide or cavity, diffusers,and performance enhancement optical elements. The light source can befluorescent tubes, incandescent bulbs or LEDs. The light source can beat the edge of the light guide or cavity (edge-lit). Or, it can be atthe bottom of the cavity or guide (bottom-lit). The light emitters,light guide/cavity and diffusers together form a uniform extendedsurface light source, which is brightest at the direction of the displaynormal. In many conditions, such as desktop monitors of personalcomputers, it is desirable to have a display being brightest at thedisplay normal. In fact, there are products, such as the brightnessenhancement (BEF) films from 3M Company that are used to enhance thebrightness of the display at the display normal, at the cost of reducingthe brightness at larger viewing angles. BEF films have a prismaticsurface and a essentially flat surface. The prismatic surface of the BEFfilm faces the rear substrate of the display panel in its intended use.

As discussed in previous paragraphs, at certain circumstances, it ishighly desirable to have a display that is bright at large viewingangles and even brighter than at display normal. This invention providesways of increasing the brightness at the primary viewing envelopes thatare away from the display normal. The key element of this invention, thelight re-distributor (LRD), uses the principles of light diffraction andscattering to re-distribute the light output from the diffuser of thebacklight assembly between the viewing envelopes. In one embodiment, theLRD is constructed as a thin optical element with interlaced lightre-directing portion and light straight transmission portion. Theviewing angles at which the display is brightest are mostly determinedby the surface profile of light re-directing portion. The ratio of thesetwo portions determines the ratio of the brightness between the viewingenvelopes. In another embodiment, a commercially available BEF film anda diffuser film are used together to achieve the desired effect. BEFfilms are intended to be used and have been used by others to increasethe brightness at the display normal. We use the BEF film in a way thathas not been used before. That is, we use the film with the prismaticside facing the backlight assembly. And, using the BEF film only isoften not enough to achieve the goal. We add a diffuser film with theright scattering power to adjust the ratio of the light between theviewing envelopes and to smooth out the boundaries between the primaryand secondary envelopes so that the artifact mentioned earlier will notbe observed.

These and other advantages, features, and objects of the presentinvention will be more readily understood in view of the followingdetailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can be more readily understood in conjunction withthe accompanying drawings, in which:

FIG. 1 is a schematic diagram illustrating the structure of the priorart.

FIG. 2 is a schematic diagram of a flat panel display implementing thepresent invention.

FIG. 3 is a schematic diagram illustrating one preferred embodiment ofthe LRD in the present invention.

FIG. 4 is a schematic diagram illustrating another preferred embodimentof the LRD in the present invention.

FIGS. 5A to 5C are experiment data as examples of the effects achievedby the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Turning to FIG. 2, a schematic diagram is provided of a flat paneldisplay implementing the present invention. Light comes from the lightemitters 22 mounted on support 21. The light emitters can be fluorescenttubes, LEDs, electroluminescent or incandescent bulbs etc. Light is thenintegrated by the cavity or light guide 23 with diffuser/reflector wallsto form a uniform extended surface source. If this light source is useddirectly to illuminate the display panel 25, the display will bebrightest at the display normal. To increase the brightness of thedisplay at the primary viewing envelopes that are away from the displaynormal, we add an optical element, the light re-distributor 24 inbetween the backlight cavity and display panel 25. The working principleof the LRD 24 can be readily understood with the assist of FIG. 3. TheLRD contains an essentially segmented surface 31 and an essentially flatsurface 32. The segmented surface consists of different portions,including a light re-directing portion 33 with surface elements formingcertain angles to the flat surface 32. The line segments of 33 can bestraight so that each segment forms a portion of a prism with the flatsurface 32. A prism changes the propagation direction of light rayspassing through it. The angle between the directions before and afterpassing the prism is determined by the angle that the light re-directingportion 33 makes to the flat surface. The light re-directing portion 33has multiple segments; each can make a different angle with thesubstrate so that it can direct light into multiple directions. Thesegments of the light re-directing portion 33 can also be curved so thatthey can direct parallel light rays hitting different points at asegment into a continuous range of different directions.

The light straight transmission portion 34 is mostly flat so that lightrays passing through this portion essentially without changingdirection. The boundaries between the re-direct and straighttransmission portions, however, should preferably be smooth to avoidlight scattering that causes a decrease of transmittance.

The pattern on the light redistribution side of a LRD can be periodic.The pitch of it can very from the order of 10 microns to the order of100 microns. If the pitch is too small, being comparable to thewavelength of the light, the light wave interference effect would causebrightness modulations and strong color dispersions. If the pitch is toolarger, the patterns on the LRD may become visible to the viewer, whichis not desirable.

The patterns can be a two dimensional array to re-distribute light intwo dimensions. In this case, the light-redirecting portion consists oftwo-dimensional arrays of cones or domes. In certain cases, the primaryand secondary viewing envelopes cover a wide range of horizontal anglesbut covers very limited vertical angle range. An LRD withtwo-dimensional structures can be used to boost brightness at largehorizontal viewing angles and reduce brightness at large verticalviewing angle. A way of achieving this effect is to laminate two LRDfilms showed in FIG. 3 back to back with the light re-directing portionsfacing outside of the laminated structure and the stripes of lightredirecting prisms on the two outer surfaces being perpendicular to eachother.

Another embodiment of the present invention is shown in FIG. 4 where alight re-directing element 41 is laminated to a diffuser element 44through a refractive index matching adhesive 43. 42 is the substrate for41. The light re-directing element can be a commercially availableelement, such as 3M's brightness enhancement films (BEF). There are acouple of different kinds of BEF films, including regular prismaticfilms with a 90 degree prism angle and 20 to 50 micro-meter pitches,films that are the same as regular prismatic films except that the prismangle been rounded (RBEF) and films with the prism profile beingsinusoidal or wave-like (WBEF). As mentioned earlier, these films areintended to enhance the brightness of the display at the display normal.The prismatic side of the film must face the display panel in itsintended use. For the purpose of this invention, these BEF films areused in a new way that the prismatic side of the film faces thebacklight. In this way, the BEF film is found to be able to direct lightaway from the cell normal. The regular BEF films direct more light fromthe display normal into large viewing angles than the RBEF and WBEFfilms do. At the time of this invention, the WBEF films have beendiscontinued and the RBEF film is soon going to be discontinued. Wechoose to use the regular BEF film. The film has several disadvantageswhen being used for re-directing light into larger angles. 1). It showsan artifact of sharp brightness change from the secondary viewingenvelope at display normal to the primary viewing envelopes at largerangles. The artifact is very noticeable when the viewer moves his headacross the boundaries of the envelopes. 2). The ratio of the brightnessat the secondary and primary viewing envelopes is fixed and may not bedesirable. 3). The angle of the maximum brightness direction is alsofixed. To overcome these disadvantages, we laminate a diffuser 44 to theBEF film to form a LRD. The diffuser will smooth out the sharpbrightness change at the boundaries of the viewing envelopes andredefine the ratio of the brightness between different envelopes. Thediffuser should have the right scattering power and minimum absorptionof light. If it diffuses light too strong, the LRD will loss most of itslight-redistribution power. If it hardly diffuses light, then it won'tbe able to overcome the disadvantages of a BEF mentioned above. Thereare commercially available diffusers with a range of different levels ofscattering power. To increase the overall transmission of the LRD, anindex matching adhesive 43 is used to laminate the BEF film and thediffuser together.

FIGS. 5A to 5C show a few instances of the measured light distributionusing LRDs that consist of commercially available components. In themeasurement, we used a Heilmeier type of LCD [2] as the display panelthat has a symmetrical left and right viewing angle characteristics, abottom lit white LED array with reflector/diffuser/light guide asbacklight assembly. FIG. 5A compares the brightness of a display withand without a light redistribution element. As expected, the brightnesspeaks at the display normal if no LRD is present and peaks at about plusand minus 40 degrees horizontal if a BEF film is used as a LRD. It canbe seen that the BEF film decreases the brightness drastically at thedisplay normal and that the slope of the brightness curve from 0 to+/−40 degrees is steep. If a RBEF film is used as a LRD, the slope isnot as steep, shown as the solid line in FIG. 5B. This could be anadvantage of using RBEF as a LRD. A disadvantage of RBEF film is thatthe ratio of the brightness between the primary and secondary envelopesis fixed and is not adjustable. FIG. 5C shows the effect of combining aBEF film with a diffuser film. The steepness of the brightness versusviewing angle curve between the primary and secondary viewing envelopescan be adjusted by choosing diffuser films of different scatteringpower. Because diffuser films of different scattering power are readilyavailable and is very cost effective, this embodiment of laminating aBEF film with a diffuser film of certain scattering power is veryversatile for satisfying various requirements. The LRD of this type iseasy to manufacture and cost effective.

In above discussions, we use an LRD on the back of the display panel tore-distribute the light. The LRD can also be placed on top of thedisplay panel, between the display and the eyes of the viewer. Now, thelight re-directing side of the LRD should face the front substrate ofthe display and the essentially flat, light transmitting or diffusingside faces the viewer. This configuration is especially useful forredistributing the light of displays that emit light, such as fieldemission displays (FED) or organic LED (OLED) displays.

It should be expressly understood that the applications of the LRDdiscussed above could be readily extended to displays other than LCD,LED and FED displays.

The above disclosure sets forth a number of embodiments of the presentinvention. Other arrangements or embodiments, not precisely set forth,could be practiced under the teachings of the present invention and asset forth in the following claims.

1. A flat panel display with primary viewing envelopes away from the display normal, comprising: a backlight assembly for transmissive and transflective type of displays (no backlight for reflective or light-emitting displays); a light re-distributors, LRD, to re-distribute the light from the backlight and increases the brightness of the display at certain viewing angles other than the display normal. The LRD can be at the rear or front side of the display panel; a display panel to spatially modulate the light passing through the panel to form a desired pattern displaying the information. The display can be of TN type, dichroic or Heilmeier type or a light emitting display such as a FED or OLED.
 2. The flat panel display of claim 1 wherein said LRD comprises: a light re-distribution side that consists of the following portions: light redirecting portions that redirect light from the display normal (zero viewing angle) to a range of larger viewing angles and light straight-transmission portions. Light passes these portions essentially without changing directions; a light diffusing side that are essentially flat. This side could be light diffusing to further re-distribute light rays.
 3. The LRD of claim 2 wherein said light re-directing portion comprises segments directing light into different viewing envelopes/angles. The segments can be straight lines to form prism arrays together with the surface of the essentially flat side of the LRD. Each prism refracts a light ray passing through it to a different direction. The segments can also be curved so that parallel light rays entering at different points on the curve are refracted to different directions and the exiting rays will cover a continuous range of angles. Different segments may form different angles with the flat surface to direct light into different viewing envelopes.
 4. The LRD of claim 2 wherein said light re-directing portion comprises preferably periodic structures. The pitch of it can very from the order of 10 microns to the order of 100 microns. The periodic structure can be of one-dimensional so that the light re-directing portion and light straight-transmission portion forms interlacing stripes on the light-redirecting side of the LRD. The structure can also be two-dimensional so that the light-redirecting portion consists of two-dimensional arrays of cones or domes. The two dimensional function can be achieved by laminating two one-dimensional LRD back to back with light re-directing side facing outside of the laminated films and that the re-directing stripes on one outer surface being perpendicular to those on the other outer surface.
 5. The LRD of claim 2 wherein the ratio between areas of the light re-directing portions and the light straight transmission portions is determined by desired brightness ratio between the primary and secondary viewing envelopes of the display.
 6. The LRD of claim 2 wherein said light-diffusing side can be constructed by laminating a diffuser film onto the light redirecting film when diffusing is needed. The scattering (diffusing) power of the diffuser can be varied. Light diffuser (scattering power close to zero) is used when maximum ratio between the brightness at a larger viewing angle and the brightness at the display normal is desired. In extreme case, no diffusing is needed. Strong diffuser is used when a smooth brightness variation between primary and secondary viewing envelopes is desired. The light diffusing side can also be constructed by surface treatments on the side of the LRD other than the light re-directing portion is on. The surface treatments can be roughing or painting the surface with light scattering materials. The needed diffusing can also be added to the film by mixing particles to the film to form a volume diffuser.
 7. The flat panel display of claim 1 wherein said LRD can be constructed using commercially available BEF films and diffuser films. The prismatic side of the BEF film should face the backlight if the LRD is placed behind the display panel and face the display panel if the LRD is placed on top of the panel, between the display and the eyes of the viewer. Diffusers of different scattering powers can be used to achieve the desired light re-distribution effect. A refractive index matching adhesive can be placed in between the prismatic film and the diffuser film.
 8. The flat panel display of claim 1 wherein said display panel comprises a Heilmeier, or a dichroic, or a twist nemetic type of LCD or other type of displays. For cockpit applications, the display is preferably of negative mode, that is, dark background and bright activated pixels or segments. The display should have a wide horizontal viewing angle when it is primarily viewed by a viewer from left and another from right. For a Heilmeier LCD, the buffing directions on the front and rear surface should be vertical and a polarizer should then have a vertical transmission axis. The polarizer is preferably placed onto the front substrate of the Heilmeier display for two purposes: to be able to utilize a UV light blocking polarizer to block possible display degrading UV light from entering into the LCD and to be compatible with the vertical polarizers of sun-glasses.
 9. The flat panel display of claim 1 wherein said backlight comprises of light emitter(s) and a subassembly of all or partial of the following components: light guide, diffusers, and reflectors. The light emitter can be of any type such as an incandescent light bulb, an electroluminescent (EL) emitter, a cold cathode fluorescent light (CCFL) tube and an LED. The light emitter(s) can be place at the side of the backlight assembly or at the bottom of the assembly. In any case, the light emitters and the subassembly should be arranged in such a way to form a uniform extended surface light source. For bottom-lit LED backlight, it is desirable to place the LEDs geometrically uniformly distributed underneath the illuminated area. A diffuser array or a diverging lens array placed on top of the LED array is helpful in eliminating hot spots: the areas right on top of an LED being brighter than surrounding areas. 